Contacted Hughes tech support and they had no idea what caused the problem, so they sent me a new surge board. Turns out this board was a new design and it took some effort to adapt the wiring from the old to the new board. But once installed it worked as designed. Below is a picture installed, the white face denotes that thee are no problems (it turns red if a fault is found, along with an error code).
In my opinion, the original design - which relied on silicone glue to hold the connectors in place - caused an poor connection and the resulted error messages.
Now all that is left is to dress the cables, use some cable clamps and I now have my internal EMS installed. Works great being able to see actual power consumption on my iPad..